Ceiling panel with concealing flange portion



July 25, 1967 w, A, A K 3,3323% CEILING PANEL WITH CONCEALING FLANGE PORTION Filed March 19, 1965 W a 2 7r w INVENTOR.

A T TOENE'V w. A. JACK 3,332,194

CEILING PANEL WITH CONCEALING FLANGE PORTION July 25, 1967 2 Sheets-Sheet 2 Filed March 19, 1965 /30 I44 BY V, kw w 4 4 m United States Patent 3,332,194 CEILING PANEL WITH CON CEALING FLANGE PORTION William Alexander Jack, Hampton, N..I., assignor to Johns Manville Corporation, New York, N.Y., a corporation of New York Filed Mar. 19, 1965, Ser. No. 441,270 1 Claim. (Cl. 52-592) This invention relates to ceiling panels and means for supporting them in a ceiling arrangement. More particularly, the invention concerns a panel construction which permits ready removal of panels from the support system.

The invention further relates to a panel construction of increased efficiency wth respect to sound attenuation, and which provides the support system with increased protection against fire.

It is well known to support individual ceiling panels in spaced relationship to the actual ceiling structure of a room to provide a decorative and acoustically effective ceiling. The usual means of support comprises a number of spaced, elongated support runners having horizontally extending flanges on which the edge portions of the panels rest. In order to conceal the support runners from view, it is common to notch or recess the panel edges, permitting the edge portion above the slot to rest upon the support flanges and to support the panels while the edge portion beneath the slot is made to extend beneath the support flanges to hide them from view. In the usual arrangement of this type, opposite edges of the panels are supported by the spaced parallel runners while the other edges merely abut the edges of adjacent panels or are further interlocked with them in order to provide a neat joint.

A major problem with this type of arrangement, however, is that the support arrangement does not permit easy access to the space between the panels and the actual ceiling structure. Since plumbing and wiring fixtures are commonly located in this space, panels at times have to be removed in order to provide access to them. With the usual type of panel support system described above, the panels cannot be readily removed because the arrangement whereby the panel both covers the face of the support flange and rests on the upper surface of the flange prevents the panel from being manipulated and lifted out of place. Usually, it is necessary to remove the panels progressively from the edge of the ceiling, adjacent a wall, to the area at which access to the space above the panel ceiling is desired. The need for a simple panel construction which both conceals the support runner yet permits it to be readily removed is apparent.

Another problem relating to ceilings formed of panels is inadequate sound attenuation properties. Acoustical ceilings are often installed continuously over large areas of oflice space, and subsequently wall partitions are located to divide the space into individual oifices. Typically, the partitions extend only to the acoustical panels and not through to the actual ceiling structure itself. Even though the panels may be comprised of materials which have satisfactory sound absorption, sound waves which are not completely absorbed retain enough energy to be transmitted over the adjacent wall partition and down through the adjacent ceiling. A simple, efficient manner of attenuating this sound, or in other words, of placing a barrier in its path, would be desirable.

A further problem faced by ceiling panel constructions is the difliculty of obtaining a time-temperature fire rating. An adequate rating is given to a construction which does not fail structurally even though exposed to fire for a certain period of time and at a certain exposed temperature. One test of the fire resistance of a ceiling construction is given in ASTM test E 119-6l. One method of increasing the resistance of a ceiling structure to fire and resultant structural failure is to prevnt the flame from impinging on the metal support system. It would be desirable to have a panel ceiling construction in which the panels cover the support system to prevent direct impingement of the flame against the support structure and yet can be easily removed.

It is an object of the present invention to provide a ceiling panel adapted to be supported by elongated support members, yet which can be readily removed to permit access to the space above the ceiling panels.

Another object of the invention is to provide a ceiling panel which, in addition to permitting easy access to the space above it, also effectively attenuates sound.

A further object is to provide a ceiling panel the edge portions of which are arranged to prevent a flame from impinging directly on the metal support system.

The nature of the invention will be more fully understood and other objects may become apparent when the following detailed description is considered in connection with the accompanying drawing, wherein:

FIG. 1 is a pictorial representation of an installed ceiling panel arrangement;

FIG. 2 is an enlarged, transverse sectional view taken on line 2-2 of FIG. 1;

FIG. 3 is an enlarged, transverse sectional view taken on line 33 of FIG. 1;

FIG. 4 is a pictorial representation of a panel in the first stage of a removal operation;

FIG. 5 is a pictorial representation of the panel of FIG. 4 in a later stage of a removal operation, just prior to being lowered from the ceiling.

FIG. 6 is an enlarged, partial sectional view showing a modification of the edge structure supported by the support runners;

FIG. 7 is a view similar to FIG. 6, but showing a modified arrangement;

FIG. '8 is a view similar to FIG. 3, but showing a modified panel construction;

FIG. 9 is a view similar to that of FIG 2, but showing a modified panel construction; and

FIG. 10 is a view similar to that of FIG. 3, but showing the modified panel of FIG. 9.

Referring to the drawing, FIG. 1 illustrates a ceiling 10 formed of a number of individual ceiling panels 12. Each of the panels is supported at opposite ends by elongated support members which are not exposed to view in FIG. 1 but which extend in the direction of the panel joints indicated at reference numeral 14. The joints 16 are the joints between the edges of the panels which are not supported by the panel support system.

Referring to FIG. 2 the panel 18 is shown as being supported on spaced parallel support runners 20 each of which comprises a web 22 and a horizontally disposed flange portion 24 arranged with respect to the web to form a T-shaped support bar.

The panel 18 is of generally rectangular shape, having a lower exposed surface 26 and a back surface 28 unexposed to view. One side edge of the panel is provided with an extended flange 30 adjacent the back surface 28 while the opposite side edge is recessed to form a flange 32, both of which flanges are adapted to rest in the flanges 24 of the runners 20 to support the panel. A straight wall 34 connects the flange portion 30 to the beveled portion 36. At the opposite end of the panel a relatively short straight wall portion 38 connects the lower wall of the flange 32 with a horizontal surface 40, which extends beneath the flange 24 to completely cover it. A second vertical wall 42 connects the extremity of the surface with the beveled portion 44.

Thus the flange 32, wall portion 38 and surface 40 form a notch or slot into which one side of the T-flange of the runner 20 extends while the flange 30 at the opposite side of the panel is in effect a ledge overhanging the major portion of the panel. Adjacent panels 46 and 48 are identical in shape with panel 18 as far as the .edge structure supported by the runners is concerned.

Referring to FIG. 3, it will be noted that the panel 18 is not identical in this cross-sectional view to the adjacent panels 50 and 52, although it is identical in this cross-sectional view to the panel 54. The side edge portions of the panel 18 transverse to the edges supported by the runners comprise flanges 56 and 58 which extend beyond the main body portions of the panel much in the same manner as does the flange 30, illustrated in FIG. 2. Vertical walls 62 and 64 connect the flanges 56 and 58 to beveled portions 66 and 68, which in turn connect the vertical wall portions to the exposed face 26. The adjacent panels 50 and 52, however, are recessed at the back portions of the side edges parallel to the flanges 56 and 58, as indicated at reference numerals 70 and 72. This structure creates support ledges 74 and 76 on which the flanges 56 and 58, respectively, rest.

If it is desired to remove the panel 18, the edge adjacent the flange 30 is pushed upwardly to pivot the panel about the opposite flange 32 until the panel is in a position such as that indicated in FIG. 4. The panel can then be moved toward the runner 20 shown in the left portion of FIG. 4 to free the panel side edge shown at the right of FIG. 4 from the runner 20. Because the flanges 56 and 58 of panel 18 are at this point still aligned with the shoulder portion of the panels 50 and 52 adjacent to panel 18, it is necessary to tilt the panel 18 until it reaches a position such as indicated in FIG. 5, wherein the flanges 58 and 56 are no longer directly above the side edge portions of the adjacent panels. The panel 18 can then be lowered through the aperture it had occupied and removed from the ceiling arrangement.

It will be apparent from a study of FIGS. 3 to that the panel 50 could not be removed in the same manner as the panel 18 because the overlying flanges 58 of panel 18 and the flange from the other adjacent panel 54 would prevent the side edges of the panel 50 from being lifted. Should it be desired to remove the panel 50, it can be accomplished very readily by first removing panel 18, in the manner described above, and then sliding the panel 50 toward the aperture previously occupied by the panel 18. The panel 50 could then be easily lowered from the ceiling arrangement. Thus the ceiling panels of the present invention, in order to provide access to the space above them, are provided with similar edge constructions with respect to the edges supported on the support runners, but the edges at right angles thereto are complementary rather than identical. This arrangement is necessary in order to permit the panels to both conceal the support runner flanges from view and be readily removable.

Although the panels have been shown as having beveled portions at their lower corners, it is not necessary that this construction be provided since it performs substantially only a decorative function. If desired, the lower corners of the panels could be square, that is, the angle between the exposed face and the side wall could be 90 Without affecting the invention.

The arrangement described above can be utilized with any desired size of panel. As a practical matter, the panels may vary from the standard ceiling tile size of 12 inches by 12 inches to a larger size ceiling panel such as l by 2, 2 by 4, or 4' by 8. Obviously, any decorative surface can be provided on the exposed faces of the panels since their appearance has no effect on the invention.

This invention is not limited to panels formed of any particular material, although it is preferred that it have good acoustical properties. It should be of suflicient strength to enable it to be notched or recessed in the manner described above and yet support the panel structurally. Examples of such materials are mineral wool panels, cellulosic fibrous panels, plastic panels, and the like.

Referring to FIG. 6, the panel edge structure to be supported by the support runners may be modified to give the panel a higher time-temperature fire rating. In this figure the panel 78 is similar to the panel 18 described above in connection with FIGURES 2 and 3 in that it is provided with a flange 80, which rests on the flange 24 of the runner 20, and with a vertical wall portion 82, which is related to the lower surface of the flange 80 in the same manner that the wall 34 is related to the flange 30 of the panel 18. Similarly, the opposite end structure of panel 84 relates to the corresponding edge structure of the panel 18, described above in connection with FIGS. 2 and 3, in that the panel 84 has a flange 86 which is supported on the flange of the runner 20 in the same manner as the flange 32 of the panel 18. A short vertical wall portion 88 connects the lower surface of the flange 86 with a horizontal surface which extends completely across the width of the flange 24 of the runner 20 to conceal the flange from view. The vertical wall portion 92, connected to the horizontal surface 90, corresponds to the vertical surface 42 of the panel 18. The panel 78, however, is provided with a further recess at the lower edge portion thereof formed by horizontal wall surface 94, connected to the vertical surface 82, and by vertical surface 96, which joins the surface 94 at right angles thereto. The panel 84 has a corresponding ledge portion formed by horizontal surface 98 on which the surface 94 rests, and a corresponding vertical surface 100 connected at right angles to the surface 98 and opposing the vertical surface 96 of the panel 78. By this arrangement, a flame at the faces of the panels would not have a direct route to the support runner 20 due to the baflie arrangement formed by the stepped construction of the panel edge portions. In contrast to this arrangement, a flame at the face of the panels shown in FIG. 2 could go directly between the vertical side edges and impinge upon the support runner. There would be no need to change the joint construction of the panel edges running at right angles to the support runners from the construction illustrated in FIG. 3 since that construction effectively baflles or obstructs a flame from reaching the space between the panels and the ceiling structure.

Referring to FIG. 7, another modified joint arrangement is shown for preventing a flame from impinging upon the support runner 20. In this arrangement the panel 101 is provided with an extending flange portion to be supported by the flange 24 of the runner 20, but the flange 102 is considerably wider than the flanges of the previously described arrangements. The opposite end of the panel, which is identical to the illustrated edge construction of panel 104, is provided with a flange 106, to be supported by the support runner flange 24, and with an extended horizontal portion 108 for covering the surface of the flanges 24. Instead of providing a downwardly extending vertical wall connected to the horizontal surface 108, however, this arrangement provides a short vertical wall 110 which extends upwardly and is connected to another horizontal surface 112, which serves to support a part of the flange 102 of the panel 100. Connected to the surface 112 at right angles thereto is a downwardly extending vertical wall surface 114 which opposes the vertical wall surface 116 of the panel 100. By this arrangement, a flame is effectively prevented from impinging upon the support runner since even if it is somehow able to travel between the two adjacent panels, it is blocked by the lower horizontal surface of the flange 102 and prevented from moving toward the runner 20 by the relatively tight joint between the flange 102 and the upper horizontal surface 112 of the panel 104.

Although, as indicated previously, the edge construction shown in FIG. 3 generally is suflicient to prevent a flame from traveling along the joints between adjacent panels extending at right angles to the runners, in some instances it may be desirable to provide a further bafile effect. Referring to FIG. 8, this can be done by providing an additional recess or stepped portion. The panel 118 thus is provided with an outermost flange portion 120, corresponding to the flanges 56 and 58 of the panel shown in FIG. 3, and a flange portion 122 disposed inwardly of the flange 120. The corresponding edge portion of the adjacent panel is also provided with an additional stepped portion 124, 126 complementary to the flanges 120 and 122 so that the ledges 124 and 126 support the flanges of the panel 118. This arrangement does not change the manner in which the panel 118 is removed since the stepped edge portions are arranged to permit the panel to be lifted and tilted in the manner described previously.

FIGS. 9 and illustrate an arrangement which increases the sound attenuation properties of a panel without affecting the ability of the panel to be readily removed from the ceiling installation. The panel 128, shown in FIGS. 9 and 10 which correspond to the views illustrated in FIGS. 2 and 3, has a cross-sectional configuration identical to the panel 18 described previously. Instead of being formed from a single slab of material, however, the panel 128 comprises a main body 130 of material having good sound absorption properties laminated to a sheet 132 of more dense material. The sheet 132 is of the same thickness as the thickness of the flanges 30, 32 of FIG. 2 so that the panel 128 is supported by the overhanging flange portions 134 and 136 of the sheet 132, shown in FIG. 9, resting upon the flanges 24 of the runners 20. In like manner, as indicated in FIG. 10, the sheet 132 extends outwardly to form flange portions 138 and 140, which are supported on the ledge portions 142 and 144, respectively, of the adjacent panels 146 and 148. The ledge portions of these adjacent panels are formed by the lower density main body portion which extends beyond the higher density sheet edge. This arrangement permits sound to be absorbed by the relatively low density material forming the body portion 130 of the panel 128 while the higher density sheet 132 acts as a barrier to prevent sound from being transmitted through the panel into the space between panels and the actual ceiling structure and down into an adjacent module.

Although the use of a relatively high density backing sheet is discussed above only in connection with a panel configuration of the type illustrated in FIGS. 2 and 3, the same principle obviously can be applied to the configurations shown in FIGS. 6, 7 and 8.

The panel arrangement shown in FIGS. 9 and 10 is not limited to any particular materials, although the main body portion 130 of the panel and the sheet 132 should be comprised of materials having relative densities as described above. An example of such an arrangement 1s a body portion formed of mineral fibers and having a density in the range of 20-25 p.c.f. and a sheet backing material comprised of gypsum board, which has a density in the general range of 55 pct. and is a good sound attenuating material.

It should now be apparent that the present invention provides a simple, expedient means for both concealing the support runners in a ceiling panel construction while permitting any panel in the ceiling arrangement to be readily removed. This design lends itself to increasing the fire resistance of the ceiling by effectively preventing flame impingement upon the support structure, and it also lends itself very effectively to attenuating sound. Not only does the modification illustrated in FIGS. 9 and 10 permit sound to be both absorbed and attenuated but it also permits much lower density material, with the accompanying increased sound absorption, to be utilized as the main body portion of the panel since the higher density backing sheet is the material in contact with the support members.

It is to be understood that other variations and modifications of the present invention may be made without departing from the spirit of the invention. It also is to be understood that the scope of the invention is not to be interpreted as limited to the specific embodiments disclosed herein, but only in accordance with the appended claims, when read in the light of the foregoing disclosure.

What I claim is:

A ceiling panel comprising (a) a panel of generally rectangular configuration and having a back face and a front face,

(b) a first flange portion extending laterally from one side edge of the panel adjacent the back surface thereof and being adapted to rest on the flange of a support member,

(c) the opposite side edge of the panel having a slot therein adapted to receive the flange of a support member,

(d) the edge portion of the face of the panel su'bjacent the slot extending laterally beyond, and having an upwardly extending wall beyond, the edge of the panel adjacent the back surface thereof, so that the said edge portion of the panel is adapted to extend beneath a support member having a flange in the slot, and the said Wall portion is adapted to extend alongside the flange in the slot, to conceal the support member from view and protect it from direct impingement by flame from the front face of the panel in the event of a fire, and

(e) flange portions extending laterally from the other side edges of the panel adjacent the back surface thereof, the latter flange portions adapted to rest on adjacent support surfaces.

References Cited UNITED STATES PATENTS 2,283,582 5/1942 Scherer 52-622 X 2,667,667 2/1954 Jacobson 52-490 X 3,001,616 9/1961 Griflin 52475 X 3,032,833 5/1962 Stanley 52497 X 3,122,216 2/1964 Boltz 52484 X FOREIGN PATENTS 738,967 10/ 1955 Great Britain.

220,213 2/ 1959 Australia. 1,229,129 9/ 1960 France.

JOHN E. MURTAGH, Primary Examiner.

G. W. HORNADAY, Assistant Examiner. 

